Reinforced flame retardant polycarbonate composition and molded article comprising same

ABSTRACT

The invention concerns polymer compositions comprising 20-80 weight percent polycarbonate polymer, 15-40 weight percent filler and 4-20% flame retardant and articles comprising same.

BACKGROUND

The development of improved thermoplastic compositions, e.g., reinforcedpolycarbonate compositions, with robust flame-retardant propertiespresents significant technical challenges in discovering compositionsthat maintain the appropriate balance of modulus, ductility, flow, thinwall flame retardancy and heat resistance. For example, the modulus canbe improved with the addition of inorganic fillers, however, the impacttoughness will significantly drop compared to unfilled compositions. Theuse of blended thermoplastic compositions in the application ofelectrical and electronic fields, especially the consumer electronicsindustry, increasingly requires compositions able to the meet thestringent requirements pertaining to modulus, flow, appearance, flameretardance, and heat resistance as these compositions are being utilizedin applications with thin wall design. In particular, the industry has astrong need for compositions capable of high modulus and high ductility,together with good processability, flawless cosmetics, and thin wallflame retardancy.

Thus, there remains a need for compositions that better manage theappropriate balance of stiffness and ductility while retaining abalanced profile of other properties. Accordingly, it would bebeneficial to provide blended thermoplastic resin compositions that havehigh modulus and high ductility while retaining appropriate balance ofother properties such as good processability, good appearance, and thinwall flame retardancy.

SUMMARY

A polymer composition comprises: a polycarbonate polymer present in anamount of about 20 weight % to about 80 weight % relative to the totalweight of the polymer composition; a polycarbonate-siloxane copolymerpresent in an amount of about 1 weight % to about 20 weight % relativeto the total weight of the polymer composition; a reinforcing fillerpresent in an amount of about 15 weight % to about 35 weight % relativeto the total weight of the polymer composition; and a flame retardantpresent in an amount of about 4 weight % to about 20 weight % relativeto the total weight of the polymer composition, wherein the flameretardant comprises phosphorus, wherein the combined weight percentvalue of all components does not exceed about 100 wt%.

A method comprises: forming a polymer composition, wherein the polymercomposition comprises: a polycarbonate polymer present in an amount ofabout 20 weight % to about 80 weight % relative to the total weight ofthe polymer composition; a polycarbonate-siloxane copolymer present inan amount of about 1 weight % to about 20 weight % relative to the totalweight of the polymer composition; a reinforcing filler present in anamount of about 15 weight % to about 35 weight % relative to the totalweight of the polymer composition; and a flame retardant present in anamount of about 4 weight % to about 20 weight % relative to the totalweight of the polymer composition, wherein the flame retardant comprisesphosphorus, wherein the combined weight percent value of all componentsdoes not exceed about 100 wt%.

A blended thermoplastic composition comprises: about 30 wt % to about 75wt % of a polycarbonate component; greater than 0 wt % to about 10 wt %of an impact modifier component; about 15 wt % to about 40 wt % of afiller component; about 5 wt % to about 20 wt % of a flame retardantcomponent; and about 0.5 wt % to about 10 wt % of a surface enhancercomponent; wherein the combined weight percent value of all componentsdoes not exceed about 100 wt %; and wherein all weight percent valuesare based on the total weight of the composition.

DETAILED DESCRIPTION

Before the present methods and systems are disclosed and described, itis to be understood that the methods and systems are not limited tospecific synthetic methods, specific components, or to particularcompositions. It is also to be understood that the terminology usedherein is for the purpose of describing particular embodiments only andis not intended to be limiting.

Various combinations of elements of this disclosure are encompassed bythis invention, e.g., combinations of elements from dependent claimsthat depend upon the same independent claim.

Moreover, it is to be understood that unless otherwise expressly stated,it is in no way intended that any method set forth herein be construedas requiring that its steps be performed in a specific order.Accordingly, where a method claim does not actually recite an order tobe followed by its steps or it is not otherwise specifically stated inthe claims or descriptions that the steps are to be limited to aspecific order, it is no way intended that an order be inferred, in anyrespect. This holds for any possible non-express basis forinterpretation, including: matters of logic with respect to arrangementof steps or operational flow; plain meaning derived from grammaticalorganization or punctuation; and the number or type of aspects describedin the specification.

It is also to be understood that the terminology used herein is for thepurpose of describing particular aspects only and is not intended to belimiting. As used in the specification and in the claims, the term“comprising” may include the aspects “consisting of” and “consistingessentially of.” Unless defined otherwise, all technical and scientificterms used herein have the same meaning as commonly understood by one ofordinary skill in the art to which this invention belongs.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a polycarbonate”includes mixtures of two or more such polycarbonates. Furthermore, forexample, reference to a filler includes mixtures of two or more suchfillers.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. A value modified by aterm or terms, such as “about” and “substantially,” is intended toinclude the degree of error associated with measurement of theparticular quantity based upon the equipment available at the time offiling this application. It will be further understood that theendpoints of each of the ranges are significant both in relation to theother endpoint, and independently of the other endpoint. It is alsounderstood that there are a number of values disclosed herein, and thateach value is also herein disclosed as “about” that particular value inaddition to the value itself. For example, if the value “10” isdisclosed, then “about 10” is also disclosed. It is also understood thateach unit between two particular units are also disclosed. For example,if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

As used herein, the terms “optional” or “optionally” mean that thesubsequently described event, condition, component, or circumstance mayor may not occur, and that the description includes instances where saidevent or circumstance occurs and instances where it does not.

Unless otherwise specified herein, any reference to standards,regulations, testing methods and the like, such as ASTM D256, ASTM D638,ASTM D790, ASTM D1238, ASTM D 4812, ASTM 4935, and UL94 refer to thestandard, regulation, guidance or method that is in force at the time offiling of the present application.

Disclosed are component materials to be used to prepare disclosedcompositions of the invention as well as the compositions themselves tobe used within methods disclosed herein. These and other materials aredisclosed herein, and it is understood that when combinations, subsets,interactions, groups, etc. of these materials are disclosed that whilespecific reference of each various individual and collectivecombinations and permutation of these compounds cannot be explicitlydisclosed, each is specifically contemplated and described herein. Forexample, if a particular compound is disclosed and discussed and anumber of modifications that can be made to a number of moleculesincluding the compounds are discussed, specifically contemplated is eachand every combination and permutation of the compound and themodifications that are possible unless specifically indicated to thecontrary. Thus, if a class of molecules A, B, and C are disclosed aswell as a class of molecules D, E, and F and an example of a combinationmolecule, A-D is disclosed, then even if each is not individuallyrecited each is individually and collectively contemplated meaningcombinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considereddisclosed. Likewise, any subset or combination of these is alsodisclosed. Thus, for example, the sub-group of A-E, B-F, and C-E wouldbe considered disclosed. This concept applies to all aspects of thisapplication including, but not limited to, steps in methods of makingand using the compositions of the invention. Thus, if there are avariety of additional steps that can be performed it is understood thateach of these additional steps can be performed with any specific aspector combination of aspects of the methods of the invention.

References in the specification and concluding claims to parts byweight, of a particular element or component in a composition or articledenotes the weight relationship between the element or component and anyother elements or components in the composition or article for which apart by weight is expressed. Thus, in a composition containing 2 partsby weight of component X and 5 parts by weight component Y, X and Y arepresent at a weight ratio of 2:5, and are present in such ratioregardless of whether additional components are contained in thecompound.

A weight percent of a component, unless specifically stated to thecontrary, is based on the total weight of the formulation or compositionin which the component is included.

Compounds disclosed herein are described using standard nomenclature.For example, any position not substituted by any indicated group isunderstood to have its valency filled by a bond as indicated, or ahydrogen atom. A dash (“-”) that is not between two letters or symbolsis used to indicate a point of attachment for a substituent. Forexample, —CHO is attached through carbon of the carbonyl group. Unlessdefined otherwise, technical and scientific terms used herein have thesame meaning as is commonly understood by one of skill in the art towhich this invention belongs.

As used herein, the terms “number average molecular weight” or “Mn” canbe used interchangeably, and refer to the statistical average molecularweight of all the polymer chains in the sample and is defined by theformula:

${{M\; n} = \frac{\sum{N_{i}M_{i}}}{\sum N_{i}}},$

where M_(i) is the molecular weight of a chain and N_(i) is the numberof chains of that molecular weight. Mn can be determined for polymers,such as polycarbonate polymers or polycarbonate-PMMA copolymers, bymethods well known to a person having ordinary skill in the art.

As used herein, the terms “weight average molecular weight” or “Mw” canbe used interchangeably, and are defined by the formula:

${{M\; w} = \frac{\sum{N_{i}M_{i}^{2}}}{\sum{N_{i}M_{i}}}},$

where Mi is the molecular weight of a chain and Ni is the number ofchains of that molecular weight. Compared to Mn, Mw takes into accountthe molecular weight of a given chain in determining contributions tothe molecular weight average. Thus, the greater the molecular weight ofa given chain, the more the chain contributes to the Mw. It is to beunderstood that as used herein, Mw is measured gel permeationchromatography. In some cases, Mw is measured gel permeationchromatography and calibrated with polycarbonate standards.

The terms “polycarbonate” or “polycarbonates” as used herein includescopolycarbonates, homopolycarbonates and (co)polyester carbonates.

The term polycarbonate can be further defined as compositions haverepeating structural units of the formula (1):

in which at least 60 percent of the total number of R¹ groups arearomatic organic radicals and the balance thereof are aliphatic,alicyclic, or aromatic radicals. In a further aspect, each R¹ is anaromatic organic radical and, more preferably, a radical of the formula(2):

-A¹-Y¹-A²-   (2),

wherein each of A¹ and A² is a monocyclic divalent aryl radical and Y¹is a bridging radical having one or two atoms that separate A¹ from A².In various aspects, one atom separates A¹ from A². For example, radicalsof this type include, but are not limited to, radicals such as —O—, —S—,—S(O)—, —S(O₂)—, —C(O)—, methylene, cyclohexyl-methylene,2-[2.2.1]-bicycloheptylidene, ethylidene, isopropylidene,neopentylidene, cyclohexylidene, cyclopentadecylidene,cyclododecylidene, and adamantylidene. The bridging radical Y¹ ispreferably a hydrocarbon group or a saturated hydrocarbon group such asmethylene, cyclohexylidene, or isopropylidene. Polycarbonate materialsinclude materials disclosed and described in U.S. Pat. No. 7,786,246,which is hereby incorporated by reference in its entirety for thespecific purpose of disclosing various polycarbonate compositions andmethods for manufacture of same.

As used herein, the term “polycarbonate-polysiloxane copolymer” isequivalent to polysiloxane-polycarbonate copolymer,polycarbonate-polysiloxane polymer, or polysiloxane-polycarbonatepolymer. In various aspects, the polycarbonate-polysiloxane copolymercan be a block copolymer comprising one or more polycarbonate blocks andone or more polysiloxane blocks. The polysiloxane-polycarbonatecopolymer comprises polydiorganosiloxane blocks comprising structuralunits of the general formula (13) below:

wherein the polydiorganosiloxane block length (E) is about 20 to about60; wherein each R group can be the same or different, and is selectedfrom a C₁₋₁₃ monovalent organic group; wherein each M can be the same ordifferent, and is selected from a halogen, cyano, nitro, C₁-C₈alkylthio, C₁-C₈ alkyl, C₁-C₈ alkoxy, C₂-C₈ alkenyl, C₂-C₈ alkenyloxygroup, C₃-C₈ cycloalkyl, C₃-C₈ cycloalkoxy, C₆-C₁₀ aryl, C₆-C₁₀ aryloxy,C₇-C₁₂ aralkyl, C₇-C₁₂ aralkoxy, C₇-C₁₂ alkylaryl, or C₇-C₁₂alkylaryloxy, and where each n is independently 0, 1, 2, 3, or 4. Thepolysiloxane-polycarbonate copolymer also comprises polycarbonate blockscomprising structural units of the general formula (14) below:

wherein at least 60 percent of the total number of R¹ groups comprisearomatic moieties and the balance thereof comprise aliphatic, alicyclic,or aromatic moieties. Polysiloxane-polycarbonates materials includematerials disclosed and described in U.S. Pat. No. 7,786,246, which ishereby incorporated by reference in its entirety for the specificpurpose of disclosing various compositions and methods for manufactureof same.

Additional components can include an impact modifier, flow modifier,filler (e.g., a particulate polytetrafluoroethylene (PTFE), glass,carbon, mineral, or metal), reinforcing agent (e.g., glass fibers),antioxidant, heat stabilizer, light stabilizer, ultraviolet (UV) lightstabilizer, UV absorbing additive, plasticizer, lubricant, release agent(such as a mold release agent), antistatic agent, anti-fog agent,antimicrobial agent, chain extender, colorant (e.g, a dye or pigment),de-molding agents, flow promoter, flow modifier, surface effectadditive, radiation stabilizer, flame retardant, anti-drip agent (e.g.,a PTFE-encapsulated styrene-acrylonitrile copolymer (TSAN)), or acombination comprising one or more of the foregoing.

In some embodiments, additives such as fillers (including reinforcingfillers), flame retardants, and surface enhancers can be added to thecompositions disclosed herein. Exemplary fillers and flame retardantsare discussed in U.S. Pat. No. 7,786,246, which is hereby incorporatedby reference in its entirety for the specific purpose of disclosingvarious compositions.

Filler components can include glass beads, glass fiber, glass flakes,mica, talc, clay, wollastonite, zinc sulfide, zinc oxide, carbon fiber(including standard carbon fiber, a performance carbon fiber, or a longcarbon fiber), ceramic-coated graphite, titanium dioxide, orcombinations thereof. Certain fillers are discussed in US 2014/0107266,which is incorporated herein in its entirety. Certain embodimentscomprise carbon fiber and/or blends with carbon fiber, and optionallyother fibers.

Flame retardants include phosphorus-containing flame retardants.Examples include phosphazene, aryl phosphate, bisphenol A disphosphate,resorcinol bis-diphenylphosphate, bisphenol A diphenyl phosphate, orresorcinol diphosphate, or a combination thereof. Certain flameretardants are discussed in US 2014/0107266, which is incorporatedherein in its entirety.

Impact modifiers include acrylonitrile-butadiene-styrene (ABS) polymercomponent, methyl methacrylate-butadiene-styrene (MBS) polymercomponent, bulk polymerized ABS (BABS) polymer, polyolefin elastomer(POE) polymer component, and silicone rubber impact modifier (SAIM)polymer component, and combinations thereof. Certain impact modifiersare discussed in US20140179817 which is incorporated herein in itsentirety.

Surface enhancer components include polyesters, a styrenic polymers(such as acrylonitrile butadiene styrene and polystyrene), polysiloxane,organomodified siloxane polymers, polyester, and maleic anhydridegrafted ethylene propylene diene monomer (MAH-g-EPDM).

Aspect 1. A polymer composition comprising: a polycarbonate polymerpresent in an amount of about 20 weight % to about 80 weight % relativeto the total weight of the polymer composition; a polycarbonate-siloxanecopolymer present in an amount of about 1 weight % to about 20 weight %relative to the total weight of the polymer composition; a reinforcingfiller present in an amount of about 15 weight % to about 35 weight %relative to the total weight of the polymer composition; and a flameretardant present in an amount of about 4 weight % to about 20 weight %relative to the total weight of the polymer composition, wherein theflame retardant comprises phosphorus.

Aspect 2. The polymer composition Aspect 1, wherein the polycarbonatepolymer comprises an aromatic polycarbonate, a polycarbonate-sebacicacid copolymer, or a branched polycarbonate, or a combination thereof,in an amount of about 5 weight % to about 30 weight % relative to thetotal weight of the polymer composition.

Aspect 3. The polymer composition of Aspect 1 or 2, wherein thereinforcing filler comprises a standard carbon fiber, a performancecarbon fiber, or a long carbon fiber, or a combination thereof; and,optionally, glass fiber.

Aspect 4. The polymer composition of any of Aspects 1-3, wherein theflame retardant comprises phosphazene, aryl phosphate, bisphenol Adisphosphate, resorcinol bis-diphenylphosphate, bisphenol A diphenylphosphate, or resorcinol diphosphate, or a combination thereof.

Aspect 5. The polymer composition of any of Aspects 1-4, furthercomprising talc present in an amount of about 0.1 weight % to about 5weight % relative to the total weight of the polymer composition.

Aspect 6. The polymer composition of any of Aspects 1-5, wherein thepolymer composition demonstrates a flexural modulus in an amount equalto or greater than about 10 GigaPascals (GPa).

Aspect 7. A method comprising: forming a blend polymer composition,wherein the blend polymer composition comprises: a polycarbonate polymerpresent in an amount of about 20 weight % to about 80 weight % relativeto the total weight of the polymer composition; a polycarbonate-siloxanecopolymer present in an amount of about 1 weight % to about 20 weight %relative to the total weight of the polymer composition; a reinforcingfiller present in an amount of about 15 weight % to about 35 weight %relative to the total weight of the polymer composition; and a flameretardant present in an amount of about 4 weight % to about 20 weight %relative to the total weight of the polymer composition, wherein theflame retardant comprises phosphorus.

Aspect 8. The method of Aspect 7, wherein the polycarbonate polymercomprises an aromatic polycarbonate, a polycarbonate-sebacic acidcopolymer, or a branched polycarbonate, or a combination thereof, in anamount of about 5 weight % to about 30 weight % relative to the totalweight of the polymer composition.

Aspect 9. The method of Aspect 7 or 8, wherein the reinforcing fillercomprises a standard carbon fiber, a performance carbon fiber, or a longcarbon fiber, or a combination thereof and, optionally, glass fiber

Aspect 10. The method of any of Aspects 7-9, wherein the flame retardantcomprises phosphazene, aryl phosphate, bisphenol A disphosphate,resorcinol bis-diphenylphosphate, bisphenol A diphenyl phosphate, orresorcinol diphosphate, or a combination thereof.

Aspect 11. The method of any of Aspects 7-10, wherein the blend polymercomposition demonstrates a flexural modulus in an amount equal to orgreater than about 10 GPa.

Aspect 12. The composition of any of Aspects 1-11, wherein a moldedsample comprising the composition has a notched Izod impact strengthgreater than or equal to about 60 Joules per meter (J/m) when tested inaccordance with ASTM D256 (greater than or equal to 100 J/m in someembodiments).

Aspect 13. The composition of any of Aspects 1-12, being capable ofachieving UL94 V0 rating at a thickness of about 0.8 millimeters (mm) toabout 1.0 mm.

Aspect 14. A blended thermoplastic composition comprising: about 30 wt %to about 75 wt % of a polycarbonate component; greater than 0 wt % toabout 10 wt % of an impact modifier component; about 15 wt % to about 40wt % of a filler component; about 5 wt % to about 20 wt % of a flameretardant component; and about 0.5 wt % to about 10 wt % of a surfaceenhancer component; wherein the combined weight percent value of allcomponents does not exceed about 100 wt %; and wherein all weightpercent values are based on the total weight of the composition.

Aspect 15. The composition of Aspect 14, wherein the polycarbonatecomponent is a homopolymer comprising repeating units derived frombisphenol-A.

Aspect 16. The composition of Aspect 14 or 15, wherein the polycarbonatehas a weight average molecular weight of about 15,000 to about 50,000grams/mole, as measured by gel permeation chromatography usingbisphenol-A polycarbonate standards.

Aspect 17. The composition of Aspect 14, wherein the polycarbonatecomponent comprises a branched chain polycarbonate.

Aspect 18. The composition of any of Aspects 14-17, wherein thepolycarbonate component comprises a blend of at least two polycarbonatepolymers.

Aspect 19. The composition of any of Aspects 14-18, wherein thepolycarbonate component comprises at least one low flow polycarbonatecomponent having a melt volume flow rate (MVR) of at least about 3.0cm³/10 minutes when measured at 300° C. and under a load of 1.2 kgaccording to ASTM D1238.

Aspect 20. The composition of any of Aspects 14-19, wherein the surfaceenhancer component comprises a polyester, a styrenic polymer, or anorganomodified siloxane.

Aspect 21. The composition of any of Aspects 14-20, wherein the impactmodifier component comprises at least oneacrylonitrile-butadiene-styrene (ABS) polymer component, at least onemethyl methacrylate-butadiene-styrene (MBS) polymer component, at leastone bulk polymerized ABS (BABS) polymer, at least one polyolefinelastomer (POE) polymer component, or at least one silicone rubberimpact modifier (SAIM) polymer component, or combinations thereof.

Aspect 22. The composition of any of Aspects 14-21, wherein the flameretardant component comprises a phosphorus-containing flame retardant.

Aspect 23. The composition of any of Aspects 14-22, wherein the fillercomponent is selected from glass beads, glass fiber, glass flakes, mica,talc, clay, wollastonite, zinc sulfide, zinc oxide, carbon fiber,ceramic-coated graphite, titanium dioxide, or combinations thereof.

Aspect 24. The composition of any of Aspects 14-23, further comprisingat least one additive selected from an anti-drip agent, antioxidant,antistatic agent, chain extender, colorant, de-molding agent, dye, flowpromoter, flow modifier, light stabilizer, lubricant, mold releaseagent, pigment, quenching agent, thermal stabilizer, UV absorbentsubstance, UV reflectant substance, and UV stabilizer, or combinationsthereof.

Aspect 25. The composition of any one of Aspects 14-24 comprising: about40 wt % to about 60 wt % of a polycarbonate component; greater than 0 wt% to about 10 wt % of an impact modifier component; about 20 wt % toabout 35 wt % of a filler component; about 5 wt % to about 20 wt % of aflame retardant component; and about 2 wt % to about 7 wt % of a surfaceenhancer component; wherein the combined weight percent value of allcomponents does not exceed about 100 wt %; and wherein all weightpercent values are based on the total weight of the composition.

Aspect 26. The composition of any one of Aspects 14-25 comprising: about30 wt % to about 75 wt % of a polycarbonate component; greater than 0 wt% to about 10 wt % of an impact modifier component; about 15 wt % toabout 40 wt % of a filler component; about 5 wt % to about 20 wt % of aflame retardant component; and about 0.5 wt % to about 10 wt % of asurface enhancer component; wherein the combined weight percent value ofall components does not exceed about 100 wt %; wherein all weightpercent values are based on the total weight of the composition.

Aspect 27. The composition of any of Aspects 14-26, wherein the blendedthermoplastic composition has a notched Izod impact strength greaterthan or equal to about 60 Jim when tested in accordance with ASTM D256.

Aspect 28. The composition of any of Aspects 14-27, wherein a moldedsample comprising the blended thermoplastic composition is capable ofachieving UL94 V0 rating at a thickness of 1.0 mm (±10%).

Aspect 29. The composition of any of Aspects 14-27, wherein a moldedsample comprising the blended thermoplastic composition is capable ofachieving UL94 V0 rating at a thickness of 1.5 mm (±10%).

Aspect 30. The composition of any of Aspects 14-29, wherein a moldedsample comprising the blended thermoplastic composition has a flexuralmodulus greater than or equal to about 5000 MegaPascals (MPa) whentested in accordance with ASTM D790.

Aspect 31. The composition of any of Aspects 14-31, wherein a moldedsample comprising the blended thermoplastic composition has having amelt flow rate (MFR) of greater than or equal to about 8 g/10 min (gramsper minute) when tested in accordance with ASTM D1238 at 260° C. under aload of 2.16 kilograms (kg).

Aspect 32. An article comprising any of the compositions of Aspects1-31.

Aspect 33. The article of Aspect 32, wherein the article is molded.

Aspect 34. The article of Aspect 33, wherein the article is selectedfrom a computer device, electromagnetic interference device, printedcircuit, Wi-Fi device, Bluetooth device, GPS device, cellular antennadevice, smart phone device, automotive device, medical device, sensordevice, security device, shielding device, RF antenna device, LED deviceand RFID device.

EXAMPLES

The following examples are put forth so as to provide those of ordinaryskill in the art with a complete disclosure and description of how themethods, devices, and systems disclosed and claimed herein are made andevaluated, and are intended to be purely exemplary and are not intendedto limit the disclosure. Efforts have been made to ensure accuracy withrespect to numbers (e.g., amounts, temperature, etc.), but some errorsand deviations should be accounted for. Unless indicated otherwise,parts are parts by weight, temperature is in degrees Celsius (° C.) oris at ambient temperature, and pressure is at or near atmospheric.

Molded articles were prepared for analysis using conventionalcompounding and molding techniques. The molded articles were compoundedat a temperature of 500° F. to 580° F. (260° C. to 304° C.).

A notched Izod impact (“NII”) test was carried out on 63.5mm×12.7mm×3.18mm molded samples (bars) according to ASTM D 256 at 23° C. Test sampleswere conditioned in ASTM standard conditions of 23° C. and 55% relativehumidity for 48 hours and then were evaluated. NII was determined usinga Ceast Impact Tester.

An unnotched Izod impact test was carried out on molded parts (bars)according to ASTM D 4812 at 23° C. Test specimen was conditioned at ASTMstandard conditions of 23° C. and 55% relative humidity for 48 hours andthen evaluated. Flexural properties (modulus and strength) were measuredusing 3.2 mm bars in accordance with ASTM D 790. Flexural strength (inunits of MPa) and flexural modulus (in units of MPa) are reported atyield. Tensile properties (modulus, strength, and strength at yield)were measured on 3.2 mm bars in accordance with ASTM D 638. Tensilestrength (for either at break or at yield, in units of MPa), tensilemodulus (in units of MPa), and tensile elongation (%) are reported atbreak. Flame retardant properties were measured in accordance with UL94flammability. Specific gravity properties were measured using ASTM D792.

Examples 1-6

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 1. The performance of the samplecompositions of polycarbonate (bisphenol-A polycarbonate),polycarbonate-siloxane copolymer (polycarbonate-siloxane block copolymerwith 20% siloxane content), and carbon fibers were tested with andwithout the addition of resorcinol diphosphate as a flame retardantcomprising phosphorus. The performance of the sample compositions werealso tested with and without the addition of talc. The samples alsoincluded a drip suppressant concentrate comprisingpolytetrafluoroethylene (PTFE). The sample compositions were producedthrough extrusion compounding, with the carbon fiber provided as choppedfeedstock. The sample compositions demonstrated acceptable ductility andstrength as measured by the flexural strength and the flexural modulus.Specific gravity was measured to characterize the sample.

Table 1 provides a performance comparison of comparative examples 1-3and inventive examples 4-6. The flame retardant properties were measuredusing the UL94 flammability test with a sample width of 1.0 mm. A ratingof V-0 demonstrates that the sample passed the UL94 test protocol;whereas a rating of NR demonstrates that the sample did not pass theUL94 test protocol by achieving any of the ratings allowed for by theUL94 test protocol.

TABLE 1 Sample characteristics Units 1 2 3 4 5 6 Polycarbonate % 53.961.6 53.9 50 48 50 PC-siloxane copolymer % 15.6 17.8 15.5 14.4 13.9 14.4Carbon fiber, performance % 20 20 30 20 20 20 Sulfonate salt % 0.3 0.3Resorcinol diphosphate % 10 12.5 12.5 15 Talc % 2.5 5 Drip suppressantconcentrate % 0.5 0.3 0.3 0.6 0.6 0.6 Specific gravity — 1.3 1.262 1.311.32 1.34 1.31 Flexural strength MPa 237 263 286 275 278 262 Flexuralmodulus MPa 18400 16200 21100 19300 20000 17000 UL94 flammability @ 1.0mm NR NR NR V-0 V-0 V-0

Examples 7-11

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 2. The performance of the samplecompositions of polycarbonate (bisphenol-A polycarbonate),polycarbonate-siloxane copolymer (polycarbonate-siloxane block copolymerwith 20% siloxane content), resorcinol diphosphate as the flameretardant comprising phosphorus, and talc were tested with performancecarbon fibers or standard carbon fibers. The sample composition alsoincluded a pentaerythritol tetrastearate, a mold release agent. Thesample compositions were produced through extrusion compounding, withthe carbon fiber provided as chopped feedstock. The sample compositionsdemonstrated acceptable ductility and strength as measured by theflexural strength and the flexural modulus. Specific gravity wasmeasured to characterize the sample.

Table 2 provides a performance comparison of inventive examples 7-11.The flame retardant properties were measured using the UL94 flammabilitytest with a sample width of 0.8 mm. A rating of V-0 demonstrates thatthe sample passed the UL94 test protocol.

TABLE 2 Sample characteristics Units 7 8 9 10 11 Polycarbonate % 52.352.3 54.4 53.4 52.4 PC-siloxane copolymer % 11.1 11.1 12 12 12 Carbonfiber, performance % 20 20 20 20 Carbon fiber, standard % 20 Resorcinoldiphosphate % 13 13 10 11 12 Talc % 2.7 2.7 2.7 2.7 2.7 Drip suppressantconcentrate % 0.6 0.6 0.6 0.6 0.6 Pentaerythritol tetrastearate % 0.30.3 0.3 0.3 0.3 Specific gravity — 1.33 1.31 1.32 1.32 1.32 Flexuralstrength MPa 287 227 258 266 261 Flexural modulus MPa 19000 14000 1850018700 18500 UL94 flammability @ 0.8 mm V-0 V-0 V-0 V-0 V-0

Examples 12-13

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 3. The performance of the samplecompositions of polycarbonate (bisphenol-A polycarbonate),polycarbonate-siloxane copolymer (polycarbonate-siloxane block copolymerwith 20% siloxane content), resorcinol diphosphate as the flameretardant comprising phosphorus, and talc were tested with long, roving,performance carbon fibers. The sample compositions were produced throughpultrusion compounding, with the carbon fiber provided as continuousfeedstock. The carbon fiber length prior to injection molding was equalto the length of the chopped pellet. These samples were molded into 6inch by 8 inch (15.24 centimeters (cm) to 20.32) plaques of 0.8 mmthickness. The sample compositions demonstrated acceptable ductility andstrength as measured by the flexural strength and the flexural modulus.Specific gravity was measured to characterize the sample.

Table 3 provides a performance comparison of inventive examples 12-13.The flame retardant properties were measured using the UL94 flammabilitytest with a sample width of 0.8 mm. A rating of V-0 demonstrates thatthe sample passed the UL94 test protocol.

TABLE 3 Sample characteristics Units 12 13 Polycarbonate % 52.6 55PC-siloxane copolymer % 10.8 9.9 Carbon fiber, performance, roving % 2020 Resorcinol diphosphate % 13 11.5 Talc % 2.7 2.7 Drip suppressantconcentrate % 0.6 0.6 Pentaerythritol tetrastearate % 0.3 0.3 Specificgravity — 1.31 1.31 Flexural strength MPa 256 244 Flexural modulus MPa17800 18200 UL94 flammability @ 0.8 mm V-0 V-0

Examples 14-17

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 4. The performance of the samplecompositions of polycarbonate (bisphenol-A polycarbonate), performancecarbon fibers, resorcinol diphosphate as the flame retardant comprisingphosphorus, and talc were tested with and without the addition ofpolycarbonate-siloxane copolymer (polycarbonate-siloxane block copolymerwith 20% siloxane content). The sample composition also includedhindered phenol stabilizer (antioxidant), phosphite stabilizer (heatstabilizer), and PC-black concentrate (colorant). The samplecompositions were produced through extrusion compounding, with thecarbon fiber provided as a chopped fiber. The sample compositionsdemonstrated acceptable ductility and strength as measured by thetensile strength, the flexural strength, and the flexural modulus.Specific gravity was measured to characterize the sample.

Table 4 provides a performance comparison of inventive example 14 tocomparative example 15 and inventive example 16 to comparative example17. The flame retardant properties were measured using the UL94flammability test with a sample width of 0.8 mm. A rating of V-0demonstrates that the sample passed the UL94 test protocol. The additionof the polycarbonate-siloxane copolymer demonstrated improved impactstrength as measured by notched Izod impact and unnotched Izod impactwhen comparing inventive example 14 to comparative example 15 andinventive example 16 to comparative example 17.

TABLE 4 Sample characteristics Units 14 15 16 17 Polycarbonate % 52.464.4 44.4 54.4 PC-siloxane copolymer % 12 10 Carbon fiber, performance %20 20 30 30 Resorcinol diphosphate % 11 11 11 11 Talc % 2.5 2.5 2.5 2.5Drip suppressant concentrate % 0.6 0.6 0.6 0.6 Pentaerythritoltetrastearate % 0.3 0.3 0.3 0.3 Hindered phenol stabilizer % 0.1 0.1 0.10.1 Phosphite stabilizer % 0.1 0.1 0.1 0.1 PC-black concentrate % 1 1 11 Specific gravity — 1.32 1.327 1.369 1.376 Tensile strength MPa 189 193192 189 Flexural strength MPa 262 256 270 258 Flexural modulus MPa 1830018300 24600 25700 Notched Izod impact J/m 72.7 56.9 66.8 50.6 UnnotchedIzod impact J/m 577 568 509 475 UL94 flammability @ 0.8 mm — V-0 V-0 V-0V-0

Examples 18-19

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 5. The performance of the samplecompositions of polycarbonate (bisphenol-A polycarbonate),polycarbonate-siloxane copolymer (polycarbonate-siloxane block copolymerwith 20% siloxane content), performance carbon fibers, and talc weretested with phosphazine as the flame retardant comprising phosphorus.The sample compositions were produced through extrusion compounding,with the carbon fiber provided as a chopped fiber. The samplecompositions demonstrated acceptable ductility and strength as measuredby the tensile strength, the flexural strength, the flexural modulus,and the notched and unnotched izod impact tests. Specific gravity wasmeasured to characterize the sample.

Table 5 provides a performance comparison of inventive examples 18-19.The flame retardant properties were measured using the UL94 flammabilitytest with a sample width of 0.8 mm. A rating of V-0 demonstrates thatthe sample passed the UL94 test protocol.

TABLE 5 Sample characteristics Units 18 19 Polycarbonate % 56.4 51.4PC-siloxane copolymer % 10 15 Carbon fiber, performance % 20 20Phosphazene % 8 8 Talc % 2.5 2.5 Drip suppressant concentrate % 0.6 0.6PETS % 0.3 0.3 Hindered phenol stabilizer % 0.1 0.1 Phosphite stabilizer% 0.1 0.1 PC-black concentrate % 2 2 Specific Gravity-Avg — 1.3 1.299Tensile strength MPa 162 156 Flexural strength MPa 241 230 Flexuralmodulus MPa 16000 16100 Notched Izod impact J/m 79.5 74.9 Unnotched Izodimpact J/m 624 559 UL94 flammability @ 0.8 mm — V-0 V-0

Examples 20-22

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 6. The performance of the samplecompositions of polycarbonate, performance carbon fibers or standardcarbon fibers, resorcinol diphosphate as the flame retardant comprisingphosphorus, and talc were tested at various sample thicknesses and withand without the addition of polycarbonate-siloxane copolymer(polycarbonate-siloxane block copolymer with 20% siloxane content). Thesample compositions were produced through extrusion compounding, withthe carbon fiber provided as a chopped fiber. The sample compositionsdemonstrated acceptable tensile strength, flexural strength, flexuralmodulus, and impact strength as shown by the notched and unnotched Izodimpact tests. Specific gravity was measured to characterize the sample.

Table 6 provides a performance comparison of inventive example 20 withcomparative examples 21 and 22. The flame retardant properties weremeasured using the UL94 flammability test with a sample width of 1.0 mmor 0.8 mm. A rating of V-0 demonstrates that the sample passed the UL94test protocol. A rating of V-1 or V-2 demonstrates inferior fireretardant properties.

TABLE 6 Sample characteristics Units 20 21 22 PC-sebacic acid copolymer% 46.4 63.4 63.4 PC-siloxane copolymer % 16 Carbon fiber, performance %20 20 Carbon fiber, standard 20 Resorcinol diphosphate % 13 13 13 Talc %2.7 2.7 2.7 Drip suppressant concentrate % 0.6 0.6 0.6 PETS % 0.3 0.30.3 PC-black concentrate % 1 Specific gravity — 1.317 1.323 1.327Tensile strength MPa 168 188 151 Flexural strength MPa 232 262 219Flexural modulus MPa 18100 18400 14200 Notched Izod impact J/m 61.1 66.446.1 Unnotched Izod impact J/m 443 567 452 UL94 flammability @ — V-0 V-0V-2 1.0 mm UL94 flammability @ — V-0 V-1 V-2 0.8 mm

Examples 23-30

As a non-limiting example, sample compositions were prepared from thecomponents described in Table 7. The performance of the samplecompositions of polycarbonate-siloxane copolymer (polycarbonate-siloxaneblock copolymer with 20% siloxane content), performance carbon fibers,and talc were tested with phosphazine or aryl phosphate as the flameretardant comprising phosphorus. The samples were also tested withpolycarbonate (bisphenol-A polycarbonate), branched polycarbonate, orpolycarbonate-sebacic acid copolymer or a combination thereof. Thesample compositions include a chain extender comprising a low molecularweight styrene-acrylate-epoxy. Various widths of the samples were usedwhen testing the flame retardant properties as measured by UL94flammability test. The sample compositions were produced throughextrusion compounding, with the carbon fiber provided as a choppedfiber. The sample compositions demonstrated acceptable ductility andstrength as measured by the tensile strength, the flexural strength, theflexural modulus, and the notched and unnotched Izod impact tests.Specific gravity was measured to characterize the sample.

Table 7 provides a performance comparison of inventive examples 23-30.The flame retardant properties were measured using the UL94 flammabilitytest with a sample width of 1.0 mm, 0.8 mm, 0.6 mm, and 0.4 mm. A ratingof V-0 demonstrates that the sample passed the UL94 test protocol.

TABLE 7 Sample characteristics Units 23 24 25 26 27 28 29 30 PC-sebacicacid copolymer % 46.95 25 25 25 25 15 37.2 34.7 Polycarbonate % 21.221.5 11.7 13.7 23.7 PC-siloxane copolymer % 15 17 17 17 15 15 17 17Branched polycarbonate % 10 10 10 10 10 Carbon fiber, performance % 2525 25 25 25 25 25 25 Phosphazene % 8 8 8 8 8 Aryl phosphate % 10 10 10Talc % 2 3 2.7 2.5 2.5 2.5 2.5 PETS % 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3Chain extender % 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Drip suppressantconcentrate % 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 Phosphite stabilizer % 0.1Hindered phenol stabilizer % 0.15 Specific gravity — 1.32 1.32 1.3 1.311.31 1.31 1.3 1.32 Tensile strength MPa 184 189 159 163 165 164 176 172Flexural strength MPa 263 276 238 246 253 251 262 262 Flexural modulusMPa 19700 19600 18900 19200 19700 19400 19500 20100 Notched Izod impactJ/m 72 82.9 74.1 82.5 80.6 77.6 74 73.4 Unnotched Izod impact J/m 458531 503 470 508 472 507 538 UL94 flammability @ 1.0 mm — V-0 V-0 V-0 V-0V-0 V-0 V-0 V-0 UL94 flammability @ 0.8 mm — V-0 V-0 V-0 V-0 V-0 V-0 V-0V-0 UL94 flammability @ 0.6 mm — — V-0 V-0 V-0 V-0 V-0 V-0 V-0 UL94flammability @ 0.4 mm — — V-0 V-0 V-0 V-0 V-0 V-0 V-0

Example 31

The materials shown in Table 8 were used to prepare the compositionsdescribed in Tables 10 and 12, and evaluated herein.

TABLE 8 Component Chemical description Source PC1 BPA polycarbonateresin made by an interfacial SABIC process with MVR at 300° C./1.2 kg ofabout 5 to Innovative about 7 mL/10 min. Plastics (“SABIC I.P.”) PC2Optical quality (OQ) BPA polycarbonate resin SABIC I.P. (with phenolendcap), MVR at 300° C./1.2 kg of about 60 to about 80 mL/10 min; Mw ofabout 17700. PC3 Branched BPA polycarbonate resin made by the SABIC I.P.interfacial process having a weight average molecular weight (Mw) of37700 and MVR at 300° C./1.2 kg of about 1 to about 4 mL/10 min. METMethyl methacrylate polymer with butyl acrylate Mitsubishi Corp. anddimethylsiloxane (CAS 143106-82-5); (HK), Ltd. available under the tradename Metablen S-2001. TALC Surface- modified talc (magnesium silicatehydrate) Imerys with a mean particle size of 1.8 microns; availableunder the trade name Luzenac ® R7. WOLL Wollastonite with median fiberdiameter of about Nyco Minerals, 4.5 μm and length of about 50 μm;available under Inc. the trade name Nyglos ® 4W 10992. GLF ChoppedE-glass fiber with an average length of Nippon Electric 4.5 mm and anaverage diameter of 13 microns; Glass Co., Ltd. available under thetrade name ECS03T-120/PL. FR1 Aromatic cyclic phosphazene-containingflame Fushimi retardant with chemical formula (C₁₂H₁₀NPO₂)_(n),Pharmaceutical wherein n is about 3 to about 6; commercially Co., Ltd.available under the trade name Rabitle FP-110. FR2 Bisphenol Abis(diphenylphosphate), CAS Reg. Daihachi No. 181028-79-5; availableunder the trade name Chemical CR-41. Industry Co., Ltd. FR3 Oligomericsolid phosphate ester flame retardant ICL Industrial with a meltingpoint of about 101-108° C.; available Products under the trade nameFyrolflex SOL-DP. ABS Bulk acrylonitrile-butadiene-styrene comprisingSABIC I.P. about 16-17 wt % butadiene content. PET Polyester homopolymerwith I.V. of about 0.800 Foshan Honghua dl/g when determined at 25° C.in a mixed solvent Polyester Chip of phenol/tetrachloroethane (1:1 byweight); Co., Ltd. available under the trade name BG-03-80. PSPolystyrene (CAS 9003-53-6) with a melt flow Styron (Hong rate (MFR) ofabout 8.5 when tested in accordance Kong) Limited with ASTM D1238 at200° C. under a 5 kg load; available under the trade name Styron 680A.SO Organomodified siloxane comprising a Evonikpolycaprolactone-polydimethylsiloxane- Goldschmidt polycaprolactonetriblock copolymer having a Mw Gmbh of about 22,000 AMU and apolydimethylsiloxane content of about 44 wt %; commercially availableunder the trade name Tegomer H-Si 6440P. TSAN Styrene-acrylonitrilecopolymer encapsulated SABIC I.P. polytetrafluoroethylene. AO1 Hinderedphenol, Irganox 1076. CIBA SPECIALITY CHEMICALS AO2Tris(2,4-di-tert-butylphenyl)phosphite, stabilizer. EVERSPRING CHEMICALCO LTD

All samples were prepared by melt extrusion on a Toshiba Twin screwextruder, using a nominal melt temperature of 260° C. and operated at400 revolutions per minute (rpm). Melt Volume Rate (“MVR”) wasdetermined at 260° C. under a 2.16 kg load, over 10 minutes, inaccordance with ASTM D1238. Each reported value is an average value ofthree tested specimens. Results are reported in cubic centimeters (cm³)per 10 minutes. Notched Izod Impact Strength (“NII”) was used to comparethe impact resistances of plastic materials and was determined inaccordance with ASTM D256 at 23° C. with a 5.5 Joule hammer using 3.2 mmthick notched Izod bars The ASTM results are defined as the impactenergy in joules used to break the test specimen, divided by thespecimen area at the notch. Results are reported in J/m. Flexuraltesting was carried out at 1.27 millimeters per minute (mm/min) inaccordance with ASTM D790.

Flammability tests following the procedure of Underwriter's LaboratoryBulletin 94 (UL94) classified results as either UL94 V0, UL94 V1, orUL94 V2 on the basis of the test results obtained for five samples.Multiple specimens (either 5 or 10) are tested per thickness. Somespecimens are tested after conditioning for 48 hours at 23° C., 50%relative humidity. The other specimens are tested after conditioning for168 hours at 70° C. The bar is mounted with the long axis vertical forflammability testing. The specimen is supported such that its lower endis 9.5 mm above the Bunsen burner tube. A blue 19 mm high flame isapplied to the center of the lower edge of the specimen for 10 seconds.The time until the flaming of the bar ceases is recorded (T1). Ifburning ceases, the flame is re-applied for an additional 10 seconds.Again, the time until the flaming of the bar ceases is recorded (T2). Ifthe specimen drips particles, these shall be allowed to fall onto alayer of untreated surgical cotton placed 305 mm below the specimen.

V0: In a sample placed so that its long axis is 180 degrees to theflame, the maximum period of flaming and/or smoldering after removingthe igniting flame does not exceed 10 seconds and none of the verticallyplaced samples produces drips of burning particles that ignite absorbentcotton, and no specimen burns up to the holding clamp after flame orafter glow.

The data were also analyzed by calculating the average flame out time,standard deviation of the flame out time and the total number of drips,and by using statistical methods to convert that data to a prediction ofthe probability of first time pass, or “p(FTP)”, that a particularsample formulation would achieve a “pass” rating in the conventionalUL94 V0 or V1 testing of 5 bars. The probability of a first time pass ona first submission (pFTP) may be determined according to the formula:

p(FTP)−(P _(t1>mbt,n=0) ×P _(t2>mbt,n=0) ×P _(total<=mbt) ×P_(drip,n=0)),

where P_(t1>mbt, n=0) is the probability that no first burn time exceedsa maximum burn time value, P_(t2>mbt, n=0) is the probability that nosecond burn time exceeds a maximum burn time value, P_(total<=mtbt) isthe probability that the sum of the burn times is less than or equal toa maximum total burn time value, and P_(drip, n=0) is the probabilitythat no specimen exhibits dripping during the flame test. First andsecond burn time refer to burn times after a first and secondapplication of the flame, respectively.

The probability that no first burn time exceeds a maximum burn timevalue, P_(t1>mbt, n=0) , may be determined the formula:

P_(t1>mbt, n=0) =(1−P _(t1>mbt))⁵,

where P_(t1>mbt) is the area under the log normal distribution curve fort1>mbt, and where the exponent “5” relates to the number of bars tested.The probability that no second burn time exceeds a maximum burn timevalue may be determined from the formula:

P_(t2>mbt, n=0) =(1−P _(t2>mbt))⁵,

where P_(t2>mbt) is the area under the normal distribution curve fort2>mbt. As above, the mean and standard deviation of the burn time dataset are used to calculate the normal distribution curve. For the UL-94V0 rating, the maximum burn time is 10 seconds. For a V1 or V2 ratingthe maximum burn time is 30 seconds. The probability P_(drip, n=0) thatno specimen exhibits dripping during the flame test is an attributefunction, estimated by:

P _(drip, n=0)=(¹ P_(drip))⁵

where P_(drip)=(the number of bars that drip/the number of bars tested).

The probability P_(total<=mtbt) that the sum of the burn times is lessthan or equal to a maximum total burn time value may be determined froma normal distribution curve of simulated 5-bar total burn times. Thedistribution may be generated from a Monte Carlo simulation of 1000 setsof five bars using the distribution for the burn time data determinedabove. Techniques for Monte Carlo simulation are well known in the art.A normal distribution curve for 5-bar total burn times may be generatedusing the mean and standard deviation of the simulated 1000 sets.Therefore, P_(total<=mtbt) may be determined from the area under a lognormal distribution curve of a set of 1000 Monte Carlo simulated 5-bartotal burn time for total≦maximum total burn time. For the UL-94 V0rating, the maximum total burn time is 50 seconds. For a V1 or V2rating, the maximum total burn time is 250 seconds. Surface appearancewas checked using the molding conditions shown in Table 9.

TABLE 9 Condition Units Pre-drying time hrs 4 Pre-drying temp ° C. 85Zone 1 temp ° C. 260 Zone 2 temp ° C. 270 Zone 3 temp ° C. 270 Nozzletemp ° C. 265 Mold temp ° C. 70

Exemplary formulations were prepared as described in Table 10 using thematerials described in Table 1, wherein all amounts are given in wt %.Data for performance of the formulations in various tests are shown inTable 11. The data show that compositions comprising 15 wt %wollastonite, 10 wt % talc and 3 wt % glass fiber had very distinctperformance results depending upon the nature of the filler, e.g.compare FR2 and FR3 individually vs. compositions comprising both FR1and FR2 or FR2 and FR3. As can be seen from Sample #1 and #2 comprising,respectively, FR2 and FR3 with different loading, but comparablephosphor content, FR3 was superior in both impact strength and flameretardance efficiency compared to FR2. Moreover, the combination of FR2and FR1 or FR2 and FR3 provided a synergistic effect, i.e. see Sample #3and #4, with robust impact and flame retardance abilities provided bythese combinations.

TABLE 10 Component #1 #2 #3 #4 PC1 20.24 21.64 21.64 21.64 PC2 15 15 1515 PC3 15 15 15 15 MET 2.5 2.5 2.5 2.5 TALC 10 10 10 10 WOLL 15 15 15 15GLF 3 3 3 3 FR1 — — — 6 FR2 10.4 — 3 3 FR3 — 9 6 — ABS 5 5 5 5

TABLE 11 Units #1 #2 #3 #4 Flexural Modulus MPa 6860 6650 6720 6680Modulus of Elasticity MPa 6190 6044 6060 6212 Tensile Stress MPa 56 5555 54 Notched Impact Strench, J/m 65 76 70 82 23° C. MFR, 260° C., 2.16Kg g/10 8.2 6.9 7.6 6.3 min App. Viscosity, 270° C., Pa*s 158 177 157179 1500 s⁻¹ Flame retardancy (UL — None V1 V1 V0 94, thickness 1.2 mm)

Additional formulations were prepared and tested (see Table 12 forformulation information and Table 13 for data obtained for formulationsof Table 12). The additional formulations further depicted theperformance of such reinforced polycarbonate compositions with theaddition of various surface enhancers. As can be seen, compared toSamples #5 and #7, which contained no surface enhancer, ABS, PET, PS andorganomodified siloxane, all manifested the function of improved surfaceappearance such as gate splay and glass floating, which are veryimportant aspects for customer judgment on the appearance of molded partwith highly filled materials. At the same time, there is still a goodbalance of material properties, for example, high modulus (7000-8000MPa) and good notched impact strength to meet the target applicationneeds.

TABLE 12 Component #5 #6 #7 #8 #9 #10 PC1 23.64 18.64 24.64 19.64 19.6424.14 PC2 15 15 15 15 15 15 PC3 15 15 15 15 15 15 MET 2.5 2.5 2.5 2.52.5 2.5 TALC 10 10 — — — — WOLL 15 15 15 15 15 15 GLF 6 6 15 15 15 15FR1 6 6 6 6 6 6 FR2 3 3 3 3 3 3 ABS — 5 — — — — PET — — — 5 — — PS — — —— 5 — SO — — — — — 0.5

TABLE 13 Unit #5 #6 #7 #8 #9 #10 Flexural Modulus MPa 7370 7310 75307660 7890 7420 Modulus of Elasticity MPa 6884 6683 7303 7972 7782 6981Tensile Stress MPa 64 62 78 81 82 75 Notched Impact J/m 71 65 99 81 8399 Strench, 23° C. MFR, 260° C., g/10 8.6 7.9 9.2 10.8 11.8 10.3 2.16 kgmin App. Viscosity, Pa*s 179 151 223 219 127 196 270° C., 1500 s⁻¹ Flameretardancy — V0 V1 V0 V0 V0 V0 (UL94, thickness 1.2 mm) SurfaceAppearance — Severe Obvious Severe Decreased Notably Obvious splaydecreased splay and glass decreased decreased splay glass floating splayand splay and floating glass glass floating floating

The disclosed formulations described hereinabove provide high ductilityin terms of notched Izod impact strength (≧80 J/m), high flexuralmodulus (≧7400 MPa), good flow (MFR≧9 g/10 min at 260° C. under a 2.16kg load), and outstanding thin wall flame retardance performance (V0<1.2mm wall thickness). The demonstrated characteristics of the disclosedformulations make them well-suited for using articles of manufacture inthe electric and electronic markets.

While aspects of the present invention can be described and claimed in aparticular statutory class, such as the system statutory class, this isfor convenience only and one of skill in the art will understand thateach aspect of the present invention can be described and claimed in anystatutory class. Unless otherwise expressly stated, it is in no wayintended that any method or aspect set forth herein be construed asrequiring that its steps be performed in a specific order. Accordingly,where a method claim does not specifically state in the claims ordescriptions that the steps are to be limited to a specific order, it isno way intended that an order be inferred, in any respect. This holdsfor any possible non-express basis for interpretation, including mattersof logic with respect to arrangement of steps or operational flow, plainmeaning derived from grammatical organization or punctuation, or thenumber or type of aspects described in the specification.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the scope or spirit of the invention. Otherembodiments of the invention will be apparent to those skilled in theart from consideration of the specification and practice of theinvention disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with a true scope and spiritof the invention being indicated by the following claims.

1. A polymer composition comprising: a polycarbonate polymer present inan amount of about 20 weight % to about 80 weight % relative to thetotal weight of the polymer composition; a polycarbonate-siloxanecopolymer present in an amount of about 1 weight % to about 20 weight %relative to the total weight of the polymer composition; a reinforcingfiller present in an amount of about 15 weight % to about 35 weight %relative to the total weight of the polymer composition; and a flameretardant present in an amount of about 4 weight % to about 20 weight %relative to the total weight of the polymer composition, wherein theflame retardant comprises phosphorus, wherein the combined weightpercent value of all components does not exceed about 100 wt %.
 2. Thepolymer composition claim 1, wherein the polycarbonate polymer comprisesan aromatic polycarbonate, a polycarbonate-sebacic acid copolymer, or abranched polycarbonate, or a combination thereof, in an amount of about5 weight % to about 30 weight % relative to the total weight of thepolymer composition.
 3. The polymer composition of claim 1, wherein thereinforcing filler comprises a standard carbon fiber, a performancecarbon fiber, or a long carbon fiber, or a combination thereof; and,optionally, glass fiber.
 4. The polymer composition of claim 1, whereinthe flame retardant comprises phosphazene, aryl phosphate, bisphenol Adisphosphate, resorcinol bis-diphenylphosphate, bisphenol A diphenylphosphate, or resorcinol diphosphate, or a combination thereof.
 5. Thepolymer composition of claim 1, further comprising talc present in anamount of about 0.1 weight % to about 5 weight % relative to the totalweight of the polymer composition.
 6. The polymer composition of claim1, wherein the polymer composition demonstrates a flexural modulus in anamount equal to or greater than about 10 GPa.
 7. The polymer compositionof claim 1, having a notched Izod impact strength of greater than orequal to 60 J/m.
 8. The polymer composition of claim 1, being capable ofachieving UL94 V0 rating at a thickness of about 0.8 mm to about 1.0 mm.9. A method comprising: forming a polymer composition, wherein thepolymer composition comprises: a polycarbonate polymer present in anamount of about 20 weight % to about 80 weight % relative to the totalweight of the polymer composition; a polycarbonate-siloxane copolymerpresent in an amount of about 1 weight % to about 20 weight % relativeto the total weight of the polymer composition; a reinforcing fillerpresent in an amount of about 15 weight % to about 35 weight % relativeto the total weight of the polymer composition; and a flame retardantpresent in an amount of about 4 weight % to about 20 weight % relativeto the total weight of the polymer composition, wherein the flameretardant comprises phosphorus, wherein the combined weight percentvalue of all components does not exceed about 100 wt %.
 10. The methodof claim 9, wherein the polycarbonate polymer comprises an aromaticpolycarbonate, a polycarbonate-sebacic acid copolymer, or a branchedpolycarbonate, or a combination thereof, in an amount of about 5 weight% to about 30 weight % relative to the total weight of the polymercomposition.
 11. The method of claim 9, wherein the reinforcing fillercomprises a standard carbon fiber, a performance carbon fiber, or a longcarbon fiber, or a combination thereof and, optionally, glass fiber 12.The method of claim 9, wherein the flame retardant comprisesphosphazene, aryl phosphate, bisphenol A disphosphate, resorcinolbis-diphenylphosphate, bisphenol A diphenyl phosphate, or resorcinoldiphosphate, or a combination thereof.
 13. A blended thermoplasticcomposition comprising: about 30 wt % to about 75 wt % of apolycarbonate component; greater than 0 wt % to about 10 wt % of animpact modifier component; about 15 wt % to about 40 wt % of a fillercomponent; about 5 wt % to about 20 wt % of a flame retardant component;and about 0.5 wt % to about 10 wt % of a surface enhancer component;wherein the combined weight percent value of all components does notexceed about 100 wt %; and wherein all weight percent values are basedon the total weight of the composition.
 14. The blended thermoplasticcomposition of claim 13, wherein the polycarbonate component is ahomopolymer comprising repeating units derived from bisphenol-A.
 15. Theblended thermoplastic composition of claim 13, wherein the polycarbonatehas a weight average molecular weight of about 15,000 to about 50,000grams/mole, as measured by gel permeation chromatography usingbisphenol-A polycarbonate standards.
 16. (canceled)
 17. (canceled) 18.(canceled)
 19. (canceled)
 20. The blended thermoplastic composition ofclaim 13 comprising: about 30 wt % to about 75 wt % of a polycarbonatecomponent; greater than 0 wt % to about 10 wt % of an impact modifiercomponent; about 15 wt % to about 40 wt % of a filler component; about 5wt % to about 20 wt % of a flame retardant component; and about 0.5 wt %to about 10 wt % of a surface enhancer component; wherein the combinedweight percent value of all components does not exceed about 100 wt %;wherein all weight percent values are based on the total weight of thecomposition.
 21. The blended thermoplastic composition of claim 13,wherein the blended thermoplastic composition has a notched Izod impactstrength greater than or equal to about 60 J/m when tested in accordancewith ASTM D256
 22. The blended thermoplastic composition of claim 13,wherein a molded sample comprising the blended thermoplastic compositionis capable of achieving UL94 V0 rating at a thickness of 1.0 mm (±10%).23. The blended thermoplastic composition of claim 13, wherein a moldedsample comprising the blended thermoplastic composition is capable ofachieving UL94 V0 rating at a thickness of 1.5 mm (±10%).
 24. Theblended thermoplastic composition of claim 13, wherein a molded samplecomprising the blended thermoplastic composition has a flexural modulusgreater than or equal to about 5000 MPa when tested in accordance withASTM D790 and having a melt flow rate (MFR) of greater than or equal toabout 8 g/10 min when tested in accordance with ASTM D1238 at 260° C.under a load of 2.16 kg.
 25. (canceled)